Intervention based completions systems and methodologies

ABSTRACT

A technique facilitates intervention operations in many types of wells including horizontal, multi-zone wells. According to an embodiment, a completion is deployed in a borehole, e.g. a deviated wellbore. The completion comprises a side pocket mandrel having a docking station. In some embodiments, the completion may comprise a plurality of the side pocket mandrels A device, such as an electrically powered device, is removably deployed in the docking station. When the docking station receives the electrically powered device, an inductive coupler or other suitable electric coupler may be used to provide power to the electrically powered device while deployed in the docking station. The electrically powered device also is configured for engagement with a tool which enables an intervention operation by simply removing and replacing the device via the tool.

CROSS-REFERENCE TO RELATED APPLICATION

The present document is based on and claims priority to U.S. Provisional Application Ser. No. 62/581,854, filed Nov. 6, 2017, which is incorporated herein by reference in its entirety.

BACKGROUND

In a variety of well applications, a wellbore is initially drilled, cased, perforated, and completed. Many types of completions are deployed downhole and such completions may comprise various components which are actuated between different operational modes. For example, the type of completion may vary depending on whether the wellbore is a generally vertical wellbore or a deviated wellbore, e.g. a horizontal wellbore. In some applications, the well may comprise a plurality of horizontal wellbores extending through multiple well zones. In each well zone, the multi-zone completion may comprise various types of components, e.g. flow control valves and other actuatable components. Intervention operations may be used to perform desired downhole actions such as actuation, removal, and/or servicing of flow control devices and other components. However, intervention operations can become difficult, costly, and time-consuming with a variety of wells such as horizontal, multi-zone wells.

SUMMARY

In general, a system and methodology facilitate intervention operations in many types of wells including horizontal, multi-zone wells. According to an embodiment, a completion is deployed in a borehole, e.g. a deviated wellbore. The completion comprises a side pocket mandrel having a docking station. In some embodiments, the completion may comprise a plurality of the side pocket mandrels with corresponding docking stations. A device, such as an electrically powered device, is removably deployed in the docking station. When the docking station receives the electrically powered device, an inductive coupler or other suitable electric coupler may be used to provide power to the electrically powered device while deployed in the docking station. The electrically powered device also is configured for engagement with a tool, e.g. a kickover tool, which enables an intervention operation by simply removing and replacing the device via the tool. For example, the ability to intervene and replace devices enables construction of a reconfigurable inflow control completion.

However, many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein, and:

FIG. 1 is an illustration of an example of a completion system deployed in a borehole and having at least one side pocket mandrel containing a removable device configured for removal via a suitable tool, e.g. a kickover tool, according to an embodiment of the disclosure;

FIG. 2 is a schematic cross-sectional illustration of an example of a portion of the completion system having a side pocket mandrel with a removable device docked therein, according to an embodiment of the disclosure;

FIG. 3 is schematic cross-sectional illustration of another example of a completion system having side pocket mandrels, according to an embodiment of the disclosure;

FIG. 4 is a schematic cross-sectional illustration of an example of a side pocket mandrel with a removable electrically powered device docked therein, according to an embodiment of the disclosure;

FIG. 5 is a schematic illustration showing use of a kickover tool to perform an intervention operation with respect to the removable electrically powered device, according to an embodiment of the disclosure; and

FIG. 6 is a schematic illustration of an example of a kickover tool system deployed downhole through the completion system for performance of an intervention operation, according to an embodiment of the disclosure.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

The present disclosure generally relates to a well system and methodology involving wellbore operations and equipment. For example, the system and methodology may be used to facilitate intervention operations in many types of wells including horizontal, multi-zone wells. According to an embodiment, a completion is deployed in a borehole, e.g. a deviated wellbore. The completion comprises a side pocket mandrel having a docking station, e.g. a plurality of the side pocket mandrels having corresponding docking stations.

A device, such as an electrically powered device, is removably deployed in each docking station. When a docking station receives the electrically powered device, an inductive coupler or other suitable electric coupler may be used to provide power to the electrically powered device while deployed in the docking station. Depending on the application, the electrically powered device may be in the form of a flow control valve, a sensor system, a sensor system combined with a flow control valve, and/or another type of removable device. In some embodiments a plurality of removable flow control valves is docked in a plurality of the side pocket mandrels to effectively construct a reconfigurable inflow control completion. The reconfigurable inflow control completion enables easy repair and/or replacement of individual flow control valves. The electrically powered device also may be configured for engagement with a tool, e.g. a kickover tool, which enables an intervention operation by simply removing and replacing the powered device via the tool.

According to embodiments described herein, various cost reductions and time reductions may be achieved with respect to intervention operations by providing completions with reconfigurable configurations. For example, removable devices may be located in side pocket mandrels along a horizontal, multi-zone completion positioned in a horizontal wellbore. The removability of the devices facilitates easier, more cost-efficient intervention operations for replacing/upgrading the removable devices to, for example, improve flow control and/or monitoring at individual well zones.

Additionally, intervention systems described herein, e.g. wireline powered intervention systems, may be used in combination with a kickover tool in a variety of environments with many types of well completions. The various intervention systems may be constructed as through-tubing intervention systems utilizing various types of components. Examples of such components include kickover tools, strokers, anchors, tractors, and/or other suitable components for a given operation.

The intervention-based completions also may employ many types of telemetry systems, e.g. wired systems, fiber-based telemetry systems, electromagnetic telemetry systems, or other wireless telemetry systems. The removable devices also may comprise many types of devices including various flow control devices, sensors, and/or other devices which may be utilized in individual sections of the completion. Individual completion sections may be located within corresponding well zones. The completion and the intervention system may be constructed with various configurations and components to facilitate easy and cost-effective reconfiguration of the completion to address a variety of well related issues.

Referring generally to FIG. 1, an embodiment of a well system 30 is illustrated. In this example, the well system 30 comprises a completion 32 deployed in a borehole 34, e.g. a wellbore. By way of example, the completion 32 may comprise a lower completion 36 disposed in a deviated wellbore section 38, e.g. a horizontal wellbore section, of wellbore 34. The lower completion 36 may comprise a plurality of completion sections 40 disposed in corresponding well zones 42 which are isolated via isolation packers 44. The isolation packers 44 may be disposed along the lower completion 36 and expanded into sealing engagement with a surrounding wellbore surface 46. It should be noted the reservoir section along the lower completion 36 may be cased or un-cased.

In the example illustrated, each completion section 40 of lower completion 36 comprises a removable device 48 (or removable devices 48) to facilitate intervention operations and to effectively form a reconfigurable completion 32. As discussed in greater detail below, the removable devices 48 may be electrically powered devices and may be in the form of flow control valves, sensors, and/or other removable devices. The completion 32 effectively provides a backbone system provisioned for releasable acceptance of devices 48.

The removable devices 48 may be removably located within side pocket mandrels 50. By way of example, each completion section 40 may comprise at least one side pocket mandrel 50 into which the corresponding removable device or devices 48 may be physically and electrically docked. An electrical cable 52 may be routed down along completion 32 to provide electrical power at each side pocket mandrel 50, e.g. to power the corresponding removable device(s) 48. The electrical cable 52 may be used to carry power and data signals. It should be noted the electrical cable 52 may be part of an overall telemetry system 53 for carrying data and power signals. However, various other types of telemetry systems 53 may be employed for carrying power and/or data along at least portions of the completion 32.

In some embodiments, the lower completion 36 may comprise a single side pocket mandrel 50 with associated removable device or devices 48. However, a variety of embodiments utilize a plurality of the side pocket mandrels 50 positioned in corresponding completion sections 40 and well zones 42. Additionally, the side pocket mandrels 50 and corresponding removable devices 48 may be used in many types of boreholes 34, including wellbores which are generally vertical or deviated, e.g. horizontal.

Referring again to FIG. 1, the reconfigurable completion 32 may be constructed in various configurations with many types of components. In the example illustrated, the lower completion 36 extends down from a production packer 54 and includes a receptacle 56 for receiving an upper completion 58. The upper completion 58 may comprise tubing 60 deployed down through a casing 62.

In some embodiments, an inductive coupler 64 may be used to facilitate communication of electric signals between the upper completion 58 and the lower completion 36. In this type of embodiment, the electrical cable 52 comprises cable sections coupled with corresponding portions of the inductive coupler 64. The configuration enables communication of power and/or data between the surface and downhole devices 48 via electrical cable 52 and inductive coupler 64. In some embodiments, the upper completion 58 and the lower completion 36 may be a single string without the inductive coupler.

Referring generally to FIG. 2, an example of one of the side pocket mandrels 50 is illustrated with its corresponding electrically powered device 48. In this embodiment, the side pocket mandrel 50 comprises a docking station 66 for releasably receiving the electrically powered device 48. The electrically powered device 48 may be oriented in docking station 66 for linear sliding removal from the docking station 66 via a suitable tool, such as a kickover tool. To facilitate removal of the electrically powered device 48 and replacement with a subsequent device 48, each electrically powered device 48 may have an engagement end 68 configured for attachment to the suitable tool.

The electrically powered device 48 may receive electric power via electrical cable 52 which may comprise a conductor segment 70 by which the cable 52 provides electrical power at the corresponding side pocket mandrel 50. The electrical power may be directed to the powered device 48 via, for example, an inductive coupler or plug connector. It should be noted the electrical cable 52 also may be used for carrying data signals to and/or from the electrically powered devices 48. In some embodiments, at least portions of the cable 52 may be incorporated into the structure of completion 32. The electrical cable 52 provides electric continuity between the docking stations 66 and the surface.

In the embodiment illustrated in FIG. 2, the electrically powered device 48 is in the form of a flow control valve 72 which may be selectively actuated according to control signals provided via electrical cable 52. For example, the flow control valve 72 may be selectively actuated to an inflow position allowing inflow of well fluid. The inflowing well fluid is represented by arrows 74 as it flows from wellbore 34 into an interior 76 of lower completion 36 via a port 78. However, the flow control valve 72 also may be actuated to a flow blocking position which blocks inflow of fluid through port 78. According to some embodiments, the flow control valve 72 may be actuated to choke at intermediate positions between full-open and full-closed.

Flow control valves 72 may be removably docked in each side pocket mandrel 50 to enable control over inflow of well fluid from individual well zones 42. The individual flow control valves 72 may be selectively undocked and removed for servicing or replacement, thus providing an easily reconfigurable inflow control completion. By way of example, each flow control valve 72 may comprise a plunger 80 which is actuated via an electric motor 82 between positions allowing or blocking flow. In some embodiments, the plunger 80 and the port 78 may be constructed to cooperate in a manner which enables choking of the flow so as to allow adjustment of the amount of flow through port 78. In this manner, the inflow control may be reconfigured by adjusting the flow control valve(s) 72 to intermediate positions without a conventional intervention operation.

With additional reference to FIG. 3, the electrically powered device 48 also may comprise a sensor 84 or a plurality of sensors 84 used alone or in cooperation with flow control valve 72. In the embodiment illustrated in FIG. 3, for example, one of the sensors 84 is positioned in the same side pocket mandrel 50 with flow control valve 72 so as to monitor parameters of the inflowing fluid 74. However, individual or plural sensors 84 may be positioned in dedicated side pocket mandrels 50 as illustrated on the right side of FIG. 3.

In some applications, the removable devices 48 may comprise various combinations of sensors 84. The sensors 84 may be selectively and removably placed along the completion 32 to monitor parameters related to production of well fluids, injection of fluids, or other operational characteristics with respect to well system 30. Examples of sensors 84 include pressure sensors, temperature sensors, flowrate sensors, resistivity sensors, water cut sensors, viscosity sensors, and/or other desired sensors. It should be noted some sensors can operate without flow, e.g. pressure and temperature sensors, while some sensors utilize flow, e.g. flowrate and water cut sensors.

Whether the removable devices 48 comprise flow control valves 72, sensors 84, other types of valves, and/or other types of devices, each of the removable devices 48 may be releasably docked in the corresponding docking station 66. The releasable docking facilitates easy and cost-effective intervention operations involving removal, replacement, servicing, or otherwise reconfiguring the type and arrangement of devices 48 utilized along completion 32. By way of example, the devices 48 may be docked in corresponding docking stations 66 via linear insertion and retrieval. In some embodiments, the docking stations 66 may comprise collets or other spring-loaded retention mechanisms to releasably secure removable devices 48 in corresponding docking stations 66.

Referring generally to FIG. 4, an example of an electrically powered device 48 is illustrated as disposed in a corresponding docking station 66 and side pocket mandrel 50. In this example, the device 48 receives electrical power via a device inductive coupler 86 located proximate the electrically powered removable device 48. For example, inductive coupler 86 may be positioned within the corresponding side pocket mandrel 50 at the corresponding docking station 66.

In FIG. 4, the electrically powered device 48 is illustrated in the form of flow control valve 72 comprising plunger 80 which is shifted linearly in response to operation of motor 82 so as to selectively block or allow fluid flow through port(s) 78. In this example, a first coil 88, e.g. a male inductive coupler coil, of inductive coupler 86 is mounted on device 48 and placed in electrical communication with, for example, motor 82. With other types of electrically powered devices 48, the first coil 88 would be similarly electrically coupled to provide power to sensors 84 and/or other powered devices 48.

A second coil 90, e.g. a female inductive coupler coil, of inductive coupler 86 may be mounted in the side pocket mandrel 50. The second coil 90 may be positioned at a location which allows the second coil 90 to appropriately mate with the first coil 88 when the electrically powered device 48 is inserted into the corresponding docking station 66. In this manner, power may be transferred from electrical cable 52 to the powered device 48 while still enabling easy release and removal of power device 48 from the corresponding side pocket mandrel 50. The device inductive coupler 86 also may be used to transfer data signals to and/or from the electrically powered device 48 while the electrically powered device 48 resides in the corresponding docking station 66.

Referring generally to FIG. 5, a schematic illustration of a tool 92 is illustrated as deployed down through the interior 76 of completion 32/lower completion 36. The tool 92 comprises a tool engagement end 94 configured to engage and grip the engagement end 68 of electrically powered device 48. By way of example, the tool engagement end 94 may comprise a spring-loaded catch or other feature constructed to securely grip the engagement end 68.

In the illustrated example, the tool 92 is in the form of a kickover tool 96 having a movable kickover portion 98. The kickover portion 98 may be controlled to move the tool engagement end 94 laterally with respect to a longitudinal axis 100 of the kickover tool 96 so as to facilitate engagement with device end 68. The kickover tool 96 may be constructed with various configurations, including configurations used in existing kickover tools such as the kickover tools available from Schlumberger Corporation. Depending on the application, the tool engagement end 94 may be constructed similarly to engagement ends utilized on existing kickover tools.

In an operational example, the kickover tool 96 is deployed along interior 76 into proximity with a desired side pocket mandrel 50. The kickover portion 98 may then be actuated to move tool engagement end 94 laterally with respect to the longitudinal axis 100 so as to engage the engagement end 68 of the corresponding device 48. The kickover tool 96 may then simply be withdrawn so as to linearly withdraw the electrically powered device 48 from its corresponding docking station 66.

The device 48 may be retrieved to the surface and replaced with another device 48, e.g. a different device or an upgraded, repaired, and/or serviced device 48. For example, the device 48 may be replaced by using the kickover tool 96 (or other suitable tool 92) to deliver the replacement device 48 down through completion 32/36 and into the appropriate docking station 66. Electrical communication may be established via device inductive coupler 86 or via other suitable electrical coupling techniques.

Referring generally to FIG. 6, an example of a system for deploying and utilizing the kickover tool 96 is illustrated for the case of horizontal completions. In this example, the kickover tool 96 is used to service a desired side pocket mandrel 50, e.g. to replace the corresponding electrically powered device 48 for a given well zone 42. The kickover tool 96 may be a wireline deployed kickover tool which is operated with the assistance of, for example, a tractor 102, an anchor 104, and a stroker 106. Depending on the application, the kickover tool 96 may be selected from one of the kickover tools available from Schlumberger Corporation.

The tractor 102 may be coupled with a wireline 108 to enable movement of the kickover tool 96 along the borehole 32, e.g. along the interior of lower completion 36 when in a generally horizontal orientation. When the kickover tool 96 is moved to a desired location proximate the side pocket mandrel 50 and device 48 of interest, the anchor 104 may be set. Once the anchor 104 is set against the surrounding completion tubing, the kickover portion 98 may be moved laterally and the stroker 106 may be controlled to move the kickover tool 96 in a linear direction. This linear motion enables engagement of the tool engagement end 94 with the corresponding engagement end 68 of device 48.

The stroker 106 may then be actuated linearly to pull the kickover tool 96 and thus the device 48 in a linear direction until undocked from the corresponding docking station 66. This undocking process may be reversed to install the subsequent device 48 in the docking station 66. This technique enables relatively quick, easy, and cost-effective interventions for servicing and replacing components along the completion 32, e.g. along a deviated lower completion 36. Additionally, the technique enables the completion 32/36 to be easily reconfigured for changing well conditions, updated components, and/or for making other desired changes.

Depending on the parameters of a given environment and wellbore application, the components utilized in well system 30 may vary. The devices 48 may comprise many types of electrically powered devices including various types of flow control valves and downhole sensors. Additionally, the completion 32 may be used in vertical wells as well as horizontal or other types of deviated wells. Similarly, the completion 32 may have a variety of components and features to address issues associated with a given production operation or other type of downhole operation.

By way of example, the completion 32 may comprise a lower completion 36 deployed in a generally horizontal borehole through multiple well zones 42. In such applications, the lower completion 36 may comprise multiple side pocket mandrels 50 containing flow control valves 72, sensors 84, and/or other types of removable devices which may be releasably docked in corresponding docking stations 66. Various types of kickover tools 96 or other suitable tools may be used for retrieving and installing the desired devices 48.

Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. 

What is claimed is:
 1. A system for use in a well, comprising: a lower completion disposed in a deviated wellbore section, the lower completion having a plurality of completion sections disposed in corresponding well zones, each completion section having a side pocket mandrel with a docking station for releasably receiving an electrically powered device, the electrically powered device being releasably docked for removal via a kickover tool.
 2. The system as recited in claim 1, wherein the electrically powered device comprises a plurality of electrically powered devices.
 3. The system as recited in claim 1, wherein the electrically powered device comprises a plurality of flow control valves which may be selectively removed via the kickover tool to provide a reconfigurable inflow control completion.
 4. The system as recited in claim 1, wherein the electrically powered device comprises a motor actuated flow control valve.
 5. The system as recited in claim 1, wherein the electrically powered device comprises a sensor.
 6. The system as recited in claim 5, wherein the sensor comprises a plurality of sensors.
 7. The system as recited in claim 2, wherein the plurality of electrically powered devices comprises a flow control valve and a sensor.
 8. The system as recited in claim 1, wherein electric power is delivered to the electrically powered device via an electric cable routed along the lower completion.
 9. The system as recited in claim 8, wherein the electric power is delivered through an inductive coupler disposed in the side pocket mandrel.
 10. A method, comprising: configuring a well completion with a plurality of docking stations that have electric continuity to the surface; removably positioning an electrically powered device in each docking station; deploying the well completion in a borehole; and using a tool to retrieve at least one of the electrically powered devices from its docking station and to replace the electrically powered device with another device.
 11. The method as recited in claim 10, further comprising: positioning each docking station in a corresponding side pocket mandrel; and providing electric power to each electrically powered device via an inductive coupler located in the corresponding side pocket mandrel.
 12. The method as recited in claim 10, wherein removably positioning the electrically powered device comprises removably positioning a flow control valve.
 13. The method as recited in claim 10, wherein removably positioning the electrically powered device comprises removably positioning a sensor.
 14. The method as recited in claim 10, wherein removably positioning the electrically powered device comprises removably positioning a flow control valve and a sensor.
 15. The method as recited in claim 10, further comprising providing electric power to the plurality of electrically powered devices via an electric cable routed along the well completion and via an inductive coupler.
 16. The method as recited in claim 10, wherein using the tool comprises using a kickover tool.
 17. The method as recited in claim 10, wherein deploying comprises deploying the well completion into a deviated wellbore.
 18. The method as recited in claim 17, further comprising: forming the well completion with a plurality of completion sections disposed in corresponding well zones; and wherein removably positioning comprises providing each completion section with at least one electrically powered device in the form of a flow control valve removably docked to establish a reconfigurable inflow control completion.
 19. A system, comprising: a completion deployed in a borehole, the completion comprising a side pocket mandrel having a docking station; and an electrically powered device removably deployed in the docking station, the electrically powered device receiving electric power through an inductive coupler, the electrically powered device having an engagement end configured for engagement with a kickover tool to enable replacement of the electrically powered device.
 20. The system as recited in claim 19, wherein the electrically powered device comprises a plurality of flow control valves, each flow control valve being selectively removable from a corresponding well zone to establish the completion as a reconfigurable inflow control completion. 